This forum needs some excitement!! DB_1's Ranger SAS rebuild

[RockRanger]

better not let stic-o beat you

 

[DB_1]

better not let stic-o beat you

I'm not worried, i've seen his lil sis Ranger project thread

Ok kiddies it's time for an update...First, I got a new toy to help out with fabbin'. It's a multitool attatchment that mounts to a bench grinder. Also got a new grinder to hook it up to since my little 5" Craftsman 1/5 hp wasn't up to the task of my fab needs. I bought a Delta 8" grinder with variable speed and it also has a light. This thing is great, it doesn't bog down at all like my Craftsman grinder did.

As for progress, I did some reworking of the axle bridge I was telling you guys about. I shortened it an inch on each side which in turn helped in lowering it.
It's all tacked up but i'm waiting for a piece of 3/16" plate to show up so I can box in the backside with it. The front of the bridge will get boxed in where there is room to do so.
I was playing around with the track bar today and got to thinking that if I rotated it so the bend angles up towards the frame as oppossed to the bend going around the diff, it might work out better. The track bar mount which I previously posted a pic of would get modified (that's becoming a common theme with this build ) because I was originally going to use a heim on that end but now it's back to the urethane mount.

On to the pics...here's the new toy:

And some shots of the axle bridge:

 

[Stic-o]

I'm not worried, i've seen his lil sis Ranger project thread

HAHA

Matt do you mail out the reamer yet?

 

[RockRanger]

Looking good Dave. Where did you get the grinder and sander deal. That looks like something I could use.

Steve. It will go out tommorow. I was trying to hold off till I got some glitter to add to the box but I havent had a chnce to get to the store to get any Ill box it up tonight and have my parents take it to the post office tommorow. Sorry for taking so long.

 

[DB_1]

I got that sander at my local welding store and it wasn't cheap...$224.00 but let me tell you, it's much more precise than any grinder and faster too. virtually burr free and leaves a nice finish. The sanding disc shows hardly any wear and i've used it a lot the past couple of days. This website has the multitool also as well as other tools to drool over:
http://vansantent.com/grinding_sanding.htm

Sears also has stand alone sanding stations starting at less than $100 that would work just as well but I needed a better grinder anyways.

 

[Stic-o]

Steve. It will go out tommorow. I was trying to hold off till I got some glitter to add to the box but I havent had a chnce to get to the store to get any Ill box it up tonight and have my parents take it to the post office tommorow. Sorry for taking so long.

No prob. Just wanted to do the knuckles, before I put them back on the axle. Thanks Matt

 

[BMXplorer]

Dave,

Good job so far on the rebuild, looks cool.

That grinder set-up is awesome.

A while back in a thread, I remember you mentioning travelling to Anaheim to check out/pick-up steel. I came across information about Industrial Metal Supply Co. to open a warehouse in Riverside which might or might not be a close Metal supplier to you. Seems like it won't be open for about a month, but could be helpful in the future. Here's a page with the information: http://tool.off-road.com/tool/article/articleDetail.jsp?id=310427

Keep up the good work, Chris

 

[DB_1]

Thanks Chris,
I've been to the IMS in Irvine and its a nice place but they don't
carry DOM tubing or at least when I went there they didn't. RockRanger has a place near him that has DOM for resonable prices and I've had him pick up some tubing for me. Whenever I decide to do a cage i'll head down there myself and pick up what I need.

Updates...well scratch what i've posted about the track bar bracket because I've fabbed up a new one. On the original one I had made you'll notice I had a tube end on there. I was going to flip the track bar (from B.C. Broncos) around and use the end with the heim on it on the axle end. After playing around with it I decided I liked the way the track bar was originally intended to be used, with the urethane bushing at the axle end. So, i've got the new bracket all tacked up and ready for final welding.

Also I've got the gussets cut out for the axle bridge, I just need to get that tacked up and then I can cut some link brackets that will be welded to the axle bridge.

The upper links are cut, just got to tack in the tube ends and weld the upper link tabs to the lower links. Those links ended up being 18" eye to eye. No real rhyme or reason to that measurement other than I was going by the upward bend in the frame...I wanted the link as long as possible without it hitting the frame on uptravel. I don't remember if i mentioned it before but my lower links are 36" eye to eye and they land exactly where the original tranny X-member was.

So what's left? As mentioned above, upper link brackets for the axle bridge need to be cut and a new track bar bracket for the frame end also needs to be cut since the one I made won't work with the new track bar bracket I just made for the axle end. The holes don't line up and I need new holes that are further out from the frame.

I'll have Friday off so I'll have 3 solid days to get some more done on my junk and I should be real close to finishing or who knows, maybe i'll suprise myself and actually get it finished!

I'll get some pics up this week.

 

[DB_1]

I got to work on the truck yesterday and today...more like half a day yesterday

Did some fine tuning to the axle bridge so it would clear/fit around the diff and got it tacked up. Also made the upper links and got the tube ends tacked on those as well.
Today I did some mock-up to see what I need to do for link tabs on top of the bridge. I had some old tabs lying around so I was able to get the links in there and get some measurements. The passenger side link tabs on the bridge sit 2" lower than the driver side...In hindsight, I should have made the pass. side of the bridge higher but oh well. Making 2 different sets of tabs was no big deal. I just have to drill the holes for the bolts and those will be finished.
I only have one more thing to fab up and that's the track bar bracket on the frame end and then it's a welding marathon. Anything and everything that attatches to the axle needs to be welded in. Then it's a few little odds and ends like fill and re-seal the front diff, find a new home for my battery and coolant overflow.
I won't be working on the truck tomorrow, got family coming out and we're doing the Easter lunch thing but i'll be back at it next week.

Here's a few pics of the mock-up:

 

[RockRanger]

looking good dave.

 

[section525]

Crazy good!

 

[DB_1]

Thanks guys...I forgot I was gonna give some specs for those who care.

Upper links are 1.5" DOM w/rock bushings (rubber) at axle end and 3/4" x 3/4" heims at the frame.

There is 8" of vertical seperation of the links at and have 6" of seperation horizontally.

That is all.

 

[Stic-o]

Hey Dave, are you still running the EB brakes? If so I got a extra set of T-bird calibers, I'll sell you cheap. They'll give you a little better stoping power

 

[FROADER]

I like the red arrow gussets.

 

[tdavis]

Why the sudden rush to get it complete Dave, you've got till November time frame before the next Truckhaven run..

 

[DB_1]

Steve,
Thanks but i'm happy with the way my brakes work

Colin,
those are the heavy duty type...you know, for off roadin'

Tom,
you're right, I think i'll take a break and pick it up again in the fall

 

[FROADER]

Tom,
you're right, I think i'll take a break and pick it up again in the fall

Hey, hey, hey...Big Bear starting at the Cleghorn trial head MAN!!

 

[DB_1]

Is Cleghorn open? I always hear rumors that it is then I later hear that it's not. Never know who to believe

 

[FROADER]

I drove past it yesterday and it was.

 

[DB_1]

That's where the confusion lies, appearantly there are 2 gates and people see the first gate open from the freeway and assume the trail is open so hard to say if it truly is open or not.